Refastenable Absorbent Article

ABSTRACT

An absorbent article is provided that comprises a front waist region, a back waist region, a crotch region disposed between the front waist region and the back waist region, a front waist end edge, a back waist end edge, a longitudinal axis extending from a mid-point of the front waist end edge to a mid-point of the back waist end edge, a first longitudinally extending side edge, a second longitudinally extending side edge, an exterior surface, an interior surface, a topsheet, a backsheet, and an absorbent core disposed between the backsheet and the topsheet. A portion of the front waist region and a portion of the back waist region are joined in a surface to surface relationship to form a pant comprising a first permanent side edge seam and a laterally opposed second permanent side edge seam. The first and second permanent side edge seams define an initial waist opening circumference and a pair of leg openings. The absorbent article comprises a first fastening component comprising a first fastening surface and a first attachment surface. The first attachment surface is disposed on the interior surface or the exterior surface of the absorbent article in the front waist region. The absorbent article comprises a second fastening component comprising a second fastening surface. The second fastening component is disposed on or forms a portion of the same surface of the absorbent article on which the first attachment surface is disposed. The initial waist opening circumference formed by the first and second permanent side edge seams is configured to be opened. The first fastening surface and the second fastening surface are configured to be refastenably engaged and separated with each other.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application Nos.61/296,686, filed on Jan. 20, 2010, and 61/296,679, filed on Jan. 20,2010, the substances of which are incorporated herein by reference.

FIELD

The present disclosure generally relates to absorbent articles andmethods for manufacturing the same, and more particularly relates torefastenable and disposable absorbent articles and methods ofmanufacturing the same.

BACKGROUND

Many refastenable pull-on disposable absorbent articles, such as pantsor diapers, for example, are provided to a consumer with fasteningcomponents initially engaged. In such structures, where first and secondfasteners or a first fastener and a second fastener, for example, areinitially engaged, the fastening components may form a pant comprisingtwo side seams, a waist opening, and two leg openings. Consumersgenerally prefer that the side seams of the pant be easily openable andreliably recloseable. Initially engaged fastening components, ifdesigned to deliver a low initial opening force, may also have a lowsubsequent opening force after reclosing of the side seams. The sideseam reopening force of an opened and reclosed side seam (i.e.,fasteners) is likely to require a lower force than the initial openingforce. Pants with a low subsequent side seam opening force may lead topoor side seam strength and a less secure closure, since the samefasteners provide not only the initial, preferably low opening force,but also must provide adequate side seam strength after refastening.What is needed is an improvement over the foregoing.

SUMMARY

In one non-limiting embodiment, the present disclosure is directed, inpart, to an absorbent article comprising a front waist region, a backwaist region, a crotch region disposed between the front waist regionand the back waist region, a front waist end edge, a back waist endedge, a longitudinal axis extending from a mid-point of the front waistend edge to a mid-point of the back waist end edge, a firstlongitudinally extending side edge, a second longitudinally extendingside edge, an exterior surface, an interior surface, a topsheet, abacksheet, and an absorbent core disposed between the backsheet and thetopsheet. A portion of the front waist region and a portion of the backwaist region are joined in a surface to surface relationship to form apant comprising a first permanent side edge seam and a laterally opposedsecond permanent side edge seam. The first and second permanent sideedge seams define an initial waist opening circumference and a pair ofleg openings. The absorbent article comprises a first fasteningcomponent comprising a first fastening surface and a first attachmentsurface. The first attachment surface is disposed on the interiorsurface or the exterior surface of the absorbent article in the frontwaist region. The absorbent article comprises a second fasteningcomponent comprising a second fastening surface. The second fasteningcomponent is disposed on or forms a portion of the same surface of theabsorbent article on which the first attachment surface is disposed. Theinitial waist opening circumference formed by the first and secondpermanent side edge seams is configured to be opened. The firstfastening surface and the second fastening surface are configured to berefastenably engaged and separated with each other.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned and other features and advantages of the presentdisclosure, and the manner of attaining them, will become more apparentand the disclosure itself will be better understood by reference to thefollowing description of non-limiting embodiments of the disclosuretaken in conjunction with the accompanying drawings, wherein:

In the drawing and in the written description, lowercase lettersappended to reference numerals indicate generally symmetric elements,e.g., left and right symmetric elements may be respectively identifiedby the reference numerals 1 a and 1 b. A reference numeral without anappended lowercase letter identifies all of the elements to which thatparticular reference numeral applies, unless otherwise indicated herein.In some instances herein, symmetric elements are referred to withoutusing such elements, e.g., 1 a and 1 b.

Common elements of various figures may not be numbered in all figuresfor simplicity. Applicants reserve the right to rely on thespecification and other figures of the specification for support. Whilecommon numbers may be used to denote particular elements in variousfigures, it will be understood that although an element has as a commonnumber, the element could be an alternative embodiment (i.e., the samenumber does not necessarily mean the element is the same, although theelement could be the same).

FIG. 1 is a plan view of a simplified absorbent article shown in itsflat, uncontracted state prior to being formed into a pant in accordancewith one non-limiting embodiment. In FIG. 1, the exterior surface of theabsorbent article is shown facing the viewer.

FIG. 2A is a cross-sectional view of the absorbent article of FIG. 1,taken along line A-A in accordance with one non-limiting embodiment.

FIG. 2B is a cross-sectional view of the absorbent article of FIG. 1,taken along line B-B in accordance with one non-limiting embodiment.

FIG. 3 is a perspective view of a pant formed from the absorbent articleof FIG. 1 joined by permanent side edge seams in accordance with onenon-limiting embodiment.

FIG. 4 is a front elevation view of a pant being worn about a lowertorso of a wearer in accordance with one non-limiting embodiment.

FIG. 5 is a rear elevation view of the pant of FIG. 4 in accordance withone non-limiting embodiment.

FIG. 6 is a left side elevation view of the pant of FIG. 4 in accordancewith one non-limiting embodiment.

FIG. 7 is a right side elevation view of the pant of FIG. 4 inaccordance with one non-limiting embodiment.

FIG. 8 is a perspective view of a pant joined by a permanent side edgeseam in accordance with one non-limiting embodiment.

FIG. 9 is a plan view of a simplified absorbent article shown in a flat,uncontracted state and configured to be formed into a pant comprising anoverlap seam in accordance with one non-limiting embodiment.

FIG. 10 is a top view of the simplified absorbent article of FIG. 9partially formed into the pant in accordance with one non-limitingembodiment.

FIG. 11 is a top view of the simplified absorbent article of FIG. 9formed into the pant in accordance with one non-limiting embodiment.

FIG. 12 is a top view of the simplified pant of FIG. 11 with separationzones separated and in a flat, uncontracted state in accordance with onenon-limiting embodiment.

FIG. 13 is a top view of the simplified pant of FIG. 12 with theseparation zones separated and first fastening components refastened toa second fastening component that is a part of, formed with, disposedon, or attached to a portion of front waist region of the pant inaccordance with one non-limiting embodiment.

FIG. 14 is a plan view of a simplified absorbent article shown in itsflat, uncontracted state prior to being formed into a pant in accordancewith one non-limiting embodiment. In FIG. 14, the exterior surface ofthe absorbent article is shown facing the viewer.

FIG. 15A is a cross-sectional view of the absorbent article of FIG. 14,taken along line A-A in accordance with one non-limiting embodiment.

FIG. 15B is a cross-sectional view of the absorbent article of FIG. 14,taken along line B-B in accordance with one non-limiting embodiment.

FIG. 16 is a perspective view of a pant formed with an overlap seam inaccordance with one non-limiting embodiment.

FIG. 17 is a cross-sectional view of the pant of FIG. 16, taken alongline D-D in accordance with one non-limiting embodiment.

FIG. 18 is a top view of a pant formed with an overlap seam inaccordance with one non-limiting embodiment.

FIG. 19 is a top view of the pant of FIG. 18 with the separation zonesseparated and the closure bonds broken. A first side of the pant isunfastened, while the second side of the pant is refastened to a frontwaist region of the pant.

FIG. 20 is a top view of a pant formed with an overlap seam inaccordance with one non-limiting embodiment.

FIG. 21 is a top view of the pant of FIG. 20 with the separation zonesseparated and the closure bonds broken. A first side of the pant isunfastened, while the second side of the pant is refastened to a frontwaist region of the pant.

FIG. 22 is top view of a pant formed with an overlap seam in accordancewith one non-limiting embodiment.

FIG. 23 is a top view of the pant of FIG. 22 with the separation zonesseparated and the closure bonds broken. A first side of the pant isunfastened, while the second side of the pant is refastened to a frontwaist region of the pant.

FIGS. 24-28 c illustrate equipment used to make the absorbent articlesof the present disclosure in accordance with various non-limitingembodiments.

Various non-limiting embodiments of the present disclosure will now bedescribed to provide an overall understanding of the principles of thestructure, function, manufacture, and use of the apparatuses and methodsdisclosed herein. One or more examples of these non-limiting embodimentsare illustrated in the accompanying drawings. Those of ordinary skill inthe art will understand that the apparatuses and methods specificallydescribed herein and illustrated in the accompanying drawings arenon-limiting example embodiments and that the scope of the variousnon-limiting embodiments of the present disclosure are defined solely bythe claims. The features illustrated or described in connection with onenon-limiting embodiment may be combined with the features of othernon-limiting embodiments. Such modifications and variations are intendedto be included within the scope of the present disclosure.

In this description, the following terms generally have the followingmeanings:

The term “absorbent article” refers to a device that is placed againstor in proximity to a body of a wearer to absorb and contain the variousexudates discharged from the body. Example absorbent articles maycomprise diapers, training pants, pants, pull-on pant-type diapers(i.e., a diaper having a pre-formed waist opening and leg openings, suchas illustrated in U.S. Pat. No. 6,120,487), refastenable diapers,incontinence briefs and undergarments, diaper holders and liners,feminine hygiene garments, and related articles.

The term “fastening component” refers to the fastening element orelements that define an area of refastenable attachment. The fasteningcomponents enable refastening of the absorbent article to reconfigurethe waist and leg openings into a closed configuration until thefastening components are separated. A fastening component may compriseof one or more refastenable fastening elements, e.g., hooks, loops,bulbs, mushrooms, arrowheads, balls on stems, buttons, snaps,refastenable cohesives, selective refastenable adhesives, etc. Afastening component may be opened and subsequently re-closed, reliably,without destroying the fastening component. A fastening componentcomprises those elements of a fastening system that form the area ofattachment via direct surface-to-surface contact forming a refastenableclosure. For the purpose of clarity, surface-to-surface contactencompasses contact between a surface of a hook material and a surfaceof as loop material, for example. For instance, a tab member joined to abacksheet would not be a fastening member as discussed. The fasteningcomponent may be the hooks or the loops that are joined to the tab andconnect with the other fastening components or a portion of an absorbentarticle.

The term “initial waist opening circumference” refers to thecircumference of a waist opening of the disposable training pant at thetime the disposable training pant is placed in the package and,subsequently, when it is removed from the package by the consumer.

The term “lateral” refers to a direction running from a side edge to anopposing side edge of the absorbent article and generally at a rightangle to the longitudinal direction. Directions within ±45° of thelateral direction are considered to be “lateral”.

The term “longitudinal” refers to a direction running from a waist edgeto an opposing waist edge of the absorbent article and generallyparallel to the maximum linear dimension of the article. Directionswithin ±45° of the longitudinal direction are considered to be“longitudinal”.

The term “pant” (also referred to as “disposable training pant,”“training pant,” and “pull-on pant-type diaper”) refers to disposableabsorbent articles having a continuous perimeter waist opening andcontinuous perimeter leg openings designed for infant, child, or adultwearers (hereafter “wearer”). A pant may be configured with a continuousor closed waist opening and at least one continuous or closed legopening prior to the pant being applied to the wearer. A pant may bepre-formed by any suitable technique including, but not limited to,joining together portions of the absorbent article using anyrefastenable and/or permanent closure member(s) (e.g., seams, heatbonds, pressure welds, adhesives, cohesive bonds, mechanical fasteners,etc.). A pant may be preformed anywhere along its circumference in thewaist region (e.g., side fastened, front waist fastened, rear waistfastened). Example pants and pant configurations are disclosed in U.S.Pat. Nos. 5,246,433, 5,569,234, 6,120,487, 6,120,489, 4,940,464,5,092,861, 5,897,545, 5,957,908, and U.S. Pat. Publ. No, 2003/0233082.

The term “secondary waist opening circumference” refers to thecircumference of the waist opening of the pant after the initial waistopening circumference has been broken and the pant has been refastened.

The term “side edge seam” refers to a given side edge wherein a portionof the side edge, or region adjacent the side edge, in the front waistregion is joined to a portion of the same side edge, or region adjacentthe side edge, in the rear waist region to define closed, encircled legopenings and a closed waist opening. Because the side edge seam isclosed with a permanent closure member, it cannot be opened withoutcausing the permanent closure member to fail (i.e., the permanentclosure member cannot again be reliably closed).

To improve the overall functionality of a refastenable side seam pant,it may be desirable to make the initial opening force and the openingforce after refastening or re-closing the pant independent of eachother. Stated another way, separate closure or fastening members may beused to create an initial waist opening circumference and a second waistopening circumference (refastened). Having fastening componentsinitially disposed in a non-engaged orientation when the initial waistopening circumference is formed makes the initial opening force of theinitial waist opening circumference independent of the opening force ofthe second waist opening circumference once the pant has been refastenedor re-closed. If the fastening components are not initially engaged, theinitial opening force may be controlled independently of the fasteningcomponents.

In one embodiment, the initial opening force may be a function of thestrength of a separation zone defined in the pant. Since the initialopening force is independent of the subsequent opening force afterrefastening, a high subsequent opening force may be delivered therebyproviding a more secure and stable side seam closure after refasteningof the side seam. In addition, a pant that has permanent side seams asthe structural elements that define the side seams, the waist opening,and the leg openings tend to deliver more robust and reliable sideseams. In one embodiment, the permanent side seams may be formed usingbonding, such as thermal bonding and/or ultrasonic bonding, for example,or may alternatively be formed using adhesives, permanent cohesives, orother suitable bonding or closure devices.

In one embodiment, both of the fastening components (i.e., firstfastening component and second fastening component) of each side seammay be disposed or formed with in the front waist region of a pant toimprove access to the fastening components. It is noted that the secondfastening component may merely be disposed on or form a portion of thefront waist region, to which the first fastening component is disposed.Improving access to the fastening components by placing the first andsecond fasting components in the front waist region may make opening andrefastening of the pant significantly easier for a caregiver and allowfront waist region to front waist region fastening, making the pantchanging or pant checking process easier for the caregiver when thewearer is standing in front of the caregiver (e.g., face-to-face) orwhen the wearer is laying on his or her back. In addition, fastening ofthe fastening components in the front waist region of a pant or diaperis also familiar to caregiver since this is similar to tape-stylediapers.

In one embodiment, both of the fastening components may also be disposedon the same surface of the pant. In one embodiment, the fasteningcomponents may both be disposed on or formed with an exterior surface ora garment-facing surface of the pant thereby making both of thefastening components readily recognizable for the caregiver, therebymaking a pant change or pant check faster and easier for the caregiver.

These pull-on training pants have proven to be particularly desirableand useful products for wearers, such as children in the potty trainingstage, for example. Such pants generally comprise an absorbent chassiscomprising a liquid impervious backsheet, a liquid pervious topsheet,and an absorbent core positioned intermediate the topsheet and thebacksheet. The absorbent chassis and the side panels (when present) maybe pre-closed to form an initial waist opening circumference and twoinitial leg opening circumferences.

Some pants have permanent side seams, or seams that cannot be refastenedonce broken, forming the leg opening circumferences and the waistopening circumference. Such permanent seams are generally pre-closed toprovide a pant that looks like underwear and may be applied likeunderwear (i.e., slid up the legs of a wearer and into position aroundthe wearer's waist region). Pants with permanent side seams, however,may require a separate element, for disposal of the pants, such as adisposal tape positioned on the external surface of the pants (such thatthe pant can be wrapped up and disposed of). Other pants havenon-permanent side seams and are refastenable thereby allowing acaregiver to open and close the waist and leg openings of the pantssimilar to a traditional tape-style diaper.

The ability to open and refasten the pants offers convenience to thecaregiver. For instance, it might be more convenient to apply the pantsas a traditional tape-style diaper when away from home or when it isinconvenient to remove the clothing and/or shoes of the wearer. Becauseit is difficult to predict when the wearer will need to be changed and,therefore, when a particular mode of application will be needed, itwould be beneficial to provide a pant that is adaptable to being appliedeither as a traditional tape-style diaper or as a disposable trainingpant. In addition, a product that may be applied like a traditionaltape-style diaper or a disposable training pant also permits inspectionof the interior of the product without having to slide the product downthe legs of the wearer. The pants of the present disclosure provide dualfunctionality with regard to application and removal while enabling theeasy wrapping up and disposal of the used pants.

Further to the above, some related art pants may be easier for a wearerto remove than the pant of the present disclosure. In related art pants,the overlap of the two portions that refasten the pants about the sideseams often creates a flap that the wearer may grasp and pull to removethe pants at an undersirable time. Because this flap generally runs fromthe waist region to the leg openings, its length allows the wearer toeasily remove the pant regardless of the wearer's dexterity. And,because the closure of the flap creates the initial waist openingcircumference of the training pant, once opened, the pant may fall offof the wearer.

To alleviate some of the problems of the related art pants, the presentdisclosure, in part, teaches a pant that minimizes the opportunity givento a wearer to remove the pant while still offering refastenableconvenience to the caregiver. The pant of the present disclosurecomprises an opening and re-closure system that require greaterdexterity to open owing at least to the location of the opening andclosure system on the pant. In one embodiment, the pant may comprise oneor more permanent side seams which form the absorbent article into thepant with pre-closed waist and leg openings and fastening componentsthat enable ease of re-closing and disposal of the pant. In oneembodiment, the opening and re-closure system may be oriented so thatthe closure member is unapparent to the wearer. Further, if the wearerdoes open the fastening components of the refastenabie closure system,the pant will not fall off since the fastening components do not, intheir initial non-engaged position, form the initial waist openingcircumference and leg opening circumferences. As a result, the pant ofthe present disclosure allows the caregiver to decide in what manner thepant will be applied to the wearer (as a pant or as a traditionaltape-style diaper). Further, the caregiver receives the added securitythat the pant may not be easily removed by the wearer. Therefore,creating a pant with the flexibility to apply as a traditionaltape-style diaper or a pant and with the aesthetics and appearance ofunderwear provides the best overall experience for the wearer and thecaregiver.

The various components used to form various example pants of the presentdisclosure will now be described in greater detail.

Absorbent Article

In one embodiment, an absorbent article may comprise a chassiscomprising a topsheet, a backsheet, and an absorbent core disposed atleast partially between the topsheet and the backsheet. The absorbentchassis may comprise a waistband, leg cuffs and or elastic strands. Invarious embodiments, referring to FIGS. 1 and 2, an example absorbentarticle 10 is shown in its flat uncontracted state prior to being formedinto a pant. The absorbent article 10 may be formed into a pant 20 shownin FIGS. 3 and 8, for example. Various suitable configurations of pant20 are disclosed in U.S. Pat. Nos. 5,246,433, 5,569,234, 6,120,487,6,120,489, 4,940,464, 5,092,861, 5,897,545, 5,957,908, and U.S. Pat.Publ. Nos. 2003/0233082, 2003/0088220, 2003/0233082, 2005/0215971,2005/0215970, 2007/0078427, 2007/0093769, 2007/0074381, 2007/0078426,2007/0078427, 2007/0093769, and 2008/0107861.

In one embodiment, referring to FIGS. 1 and 2, one end portion of theabsorbent article 10 may be configured as a front waist region 36 andthe longitudinally opposing end portion may be configured as a backwaist region 38. An intermediate portion of the absorbent article 10extending longitudinally between the front waist region 36 and the backwaist region 38 may be configured as a crotch region 37. In oneembodiment, although not illustrated as such, the length of each of thefront waist region 36, the back waist region 38 and the crotch region 37may be about ⅓ of the length of the absorbent article 10, for example.In other embodiments, the length of each of the front waist region 36,the back waist region 38, and the crotch region 37 may have otherdimensions. In various embodiments, the absorbent article 10 may have alaterally extending front waist end edge 136 in the front waist region36 and a longitudinally opposing and laterally extending back waist endedge 138 in the back waist region 38.

In one embodiment, still referring to FIGS. 1 and 2, a chassis 100 ofthe absorbent article 10 may comprise a first longitudinally extendingside edge 137 a and a laterally opposing and second longitudinallyextending side edge 137 b. Both of the side edges 137 may extendlongitudinally between the front waist end edge 136 and the back waistend edge 138. The chassis 100 may form a portion of the laterallyextending front waist end edge 136 in the front waist region 36 and aportion of the longitudinally opposing and laterally extending backwaist end edge 138 in the back waist region 38. Furthermore, the chassis100 may comprise an interior surface 102, an exterior surface 104, alongitudinal axis 42, and a lateral axis 44. The longitudinal axis 42may extend through a midpoint of the front waist end edge 136 andthrough a midpoint of the back waist end edge 138, while the lateralaxis 44 may extend through a midpoint of the first side edge 137 a andthrough a midpoint of the second side edge 137 b.

In various embodiments, a portion of or the whole absorbent article 10may be made to be laterally extensible. The extensibility of theabsorbent article 10 may be desirable in order to allow the absorbentarticle 10 to conform to a body of a wearer during movement by thewearer. The extensibility may also be desirable, for example, in orderto allow the caregiver to extend the front waist region 36, the backwaist region 38, the crotch region 37, and/or the chassis 100 to provideadditional body coverage for wearers of differing size, i.e., to tailorthe absorbent article 10 to the individual wearer. Such extension mayprovide the absorbent article 10 with a generally hourglass shape, solong as the crotch region 37 is extended to a relatively lesser degreethan the waist regions 36 and/or 38. This extension may also impart atailored appearance to the absorbent article 10 during use.

Topsheet

In one embodiment, again referring to FIGS. 1 and 2, the absorbentarticle 10 may comprise a topsheet 81. The topsheet 81 may be compliant,soft feeling, and non-irritating to the wearer's skin and may beelastically stretchable in one or more directions. Further, the topsheet81 may be liquid pervious, permitting liquids (e.g., menses, urine,and/or runny feces) to penetrate through its thickness. Varioustopsheets may also comprise a hydrophilic material, for example, whichis configured to draw bodily fluids into an absorbent core of thechassis 100 when these fluids are expelled from the body. A suitabletopsheet 81 may be manufactured from a wide range of materials, such aswoven and nonwoven materials, apertured or hydroformed thermoplasticfilms, apertured nonwovens, porous foams, reticulated foams, reticulatedthermoplastic films, and/or thermoplastic scrims, for example. Suitableapertured films may comprise those described in U.S. Pat. Nos.5,628,097, 5,916,661, 6,545,197, and 6,107,539. Apertured film topsheetstypically may be pervious to bodily exudates, yet non-absorbent, andhave a reduced tendency to allow fluids to pass back through and rewetthe wearer's skin. Suitable woven and nonwoven materials may comprisenatural fibers, such as, for example, wood or cotton fibers, syntheticfibers, such as, for example, polyester, polypropylene, or polyethylenefibers, or combinations thereof. If the topsheet 81 comprises fibers,the fibers may be spunbond, carded, wet-laid, meltblown, hydroentangled,or otherwise processed, for example, as is generally known in the art.

Backsheet

In one embodiment, referring to FIGS. 3 and 8, for example, theabsorbent article 10 may comprise a backsheet 83. In FIGS. 3 and 8, theabsorbent article 10 is shown formed into a pant 20. The backsheet 83may be impervious, or at least partially impervious, to fluids or bodyexudates (e.g., menses, urine, and/or runny feces) and may bemanufactured from a thin plastic film, although other flexible liquidimpervious materials may also be used. The backsheet 83 may prevent thebody exudates or fluids absorbed and contained in an absorbent core ofthe absorbent article 10 from wetting articles which contact theabsorbent article 10, such as bedsheets, pajamas, clothes, and/orundergarments, for example, when formed into the pant 20. The backsheet83 may comprise a woven or nonwoven material, polymeric films such asthermoplastic films of polyethylene or polypropylene, and/or amulti-layer or composite materials comprising a film and a nonwovenmaterial (e.g., having an inner film layer and an outer nonwoven layer).A suitable backsheet may comprise a polyethylene film having a thicknessof from about 0.012 mm (0.5 mils) to about 0.051 mm (2.0 mils). Examplesof polyethylene films are manufactured by Clopay Corporation ofCincinnati, Ohio, under the designation BR-120 and BR-121, and byTredegar Film Products of Terre Haute, Ind., under the designationXP-39385. In one embodiment, the backsheet 83 may be embossed and/ormatte-finished to provide a more cloth-like appearance. Further, thebacksheet 83 may permit vapors to escape from the absorbent core of theabsorbent article 10 (i.e., the backsheet 83 is breathable) while stillpreventing, or at least inhibiting, fluids or body exudates from passingthrough the backsheet 83. In one embodiment, the size of the backsheet83 may be dictated by the size of the absorbent article 10 and thedesign or configuration of the pant 20 to be formed, for example.

Absorbent Core

In various embodiments, referring to FIGS. 1 and 2, the absorbentarticle 10 may comprise an absorbent core 200 that is disposed betweenthe topsheet 81 and the backsheet 83. The absorbent core 200 maycomprise a laterally extending front edge 236 in the front waist region36, a longitudinally opposing and laterally extending back edge 238 inthe back waist region 38, a first longitudinally extending side edge 237a, and a laterally opposing and second longitudinally extending sideedge 237 b. Both of the side edges 237 may extend longitudinally betweenthe front edge 236 and the back edge 238. In one embodiment, more thanone absorbent core 200 or more than one absorbent core layer may beprovided in an absorbent article 10, for example. The absorbent core 200may be any suitable size or shape that is compatible with the absorbentarticle 10. Example absorbent structures for use as the absorbent core200 of the present disclosure that have achieved acceptance andcommercial success are described in U.S. Pat. Nos. 4,610,678, 4,673,402,4,888,231, and 4,834,735.

In one embodiment, suitable absorbent cores may comprise cellulosicairfelt material. For instance, such absorbent cores may comprise lessthan about 40%, 30%, 20%, 10%, 5%, or even 1% of the cellulosic airfeltmaterial as determined by weight. Additionally, such an absorbent coremay be primarily comprised of an absorbent gelling material in amountsof at least about 60%, 70%, 80%, 85%, 90%, 95%, or even about 100% asdetermined by weight, Furthermore, a portion of the absorbent core maycomprise a microfiber glue (if applicable). Such absorbent cores,microfiber glues, and absorbent gelling materials are described in U.S.Pat. Nos. 5,599,335, 5,562,646, 5,669,894, 6,790,798, and 7,521,587 andin U.S. Pat. Publ. No. 2004/0158212.

Leg Cuffs

In one embodiment, referring to FIGS. 1 and 2, the chassis 100 of theabsorbent article 10 may comprise longitudinally extending and laterallyopposing leg cuffs 147 a and 147 b that are disposed on the interiorsurface of the chassis 100 that faces inwardly toward the wearer andcontacts the wearer. The leg cuffs 147 a and 147 b may comprise one ormore elastic gathering members 159 disposed at or adjacent the proximaledge of one or both of the leg cuffs 147. In addition, to the elasticgathering members 159 the leg cuff may also comprise one or more elasticstrands 168 disposed at or adjacent the distal edge 139 of one or bothof the leg cuffs 147. The elasticized leg cuffs 147 may comprise severalembodiments for reducing the leakage of body exudates or fluids in theleg regions. The elasticized leg cuffs 147 are sometimes referred to asleg bands, barrier cuffs, elastic cuffs, or gasketing cuffs.) Suitableelasticized leg cuffs 147 may comprise those described in U.S. Pat. Nos.3,860,003, 4,909,803, 4,695,278, 4,795,454, 4,704,115, and 4,909,803,and U.S. Pat. Publ. No. 2009/0312730. The leg cuffs 147 may be formed byfolding portions of the chassis 100 laterally inward, i.e., toward thelongitudinal axis 42, to form both the respective leg cuffs 147 and theside edges 137 of the chassis 100. In other embodiments, the leg cuffs147 may be formed by attaching an additional layer or layers to thechassis 100 at or adjacent to each of the respective side edges 137 aand 137 b of the chassis 100. In one embodiment, the chassis 100 mayalso comprise other elastics 141 disposed adjacent the side edges 137which may cause the pant 20 to form into a “U” shape when allowed torelax thereby pulling the interior surface 102 of the front waist region36 toward the interior surface 102 of the back waist region 38.

In one embodiment, again referring to FIGS. 1 and 2, each leg cuff 147may comprise a proximal edge 157 a and 157 b. These edges 157 a and 157b are positioned proximate to the longitudinal axis 42 compared todistal edges 139 a and 139 b. The leg cuffs 147 may overlap theabsorbent core 200, i.e., the proximal edges 157 a and 157 b lielaterally inward of the respective side edges 237 a and 237 b of theabsorbent core 200. Such an overlapped configuration may be desirable inorder to impart a more finished appearance to the absorbent article 10than that imparted by a non-overlapped configuration. In otherembodiments, the leg cuffs 147 may not overlap the absorbent core 200.

In one embodiment, still referring to FIGS. 1 and 2, each leg cuff 147may be attached to the interior surface 102 of the chassis 100 in a legcuff attachment zone (not shown) adjacent to the front waist end edge136 and in a longitudinally opposing leg cuff attachment zone (notshown) adjacent to the back waist end edge 138. In one embodiment,between the leg cuff attachment zones, the proximal edge 157 of the legcuff 147 remains free, i.e., not attached to the interior surface 102 ofthe chassis 100 or to the absorbent core 200. Also, between thelongitudinally opposing leg cuff attachment zones, each leg cuff 147 maycomprise one or more (specifically including one, two, three, or fourelastic strands per leg cuff 147) longitudinally extensible cuff elasticgathering members 159 that may be disposed at or adjacent to theproximal edge 157 of the leg cuff 147 by any suitable methods. Each ofsuch cuff elastic gathering members 159 may be attached over the legcuff's entire length or over only a portion of the leg cuff's length.For example, such cuff elastic gathering members 159 may be attachedonly at or near the leg cuff's longitudinally opposing ends and may beunattached at the middle of the leg cuff's length. Such cuff elasticgathering members 159 may be disposed in the crotch region 37 and mayextend into one or both of the front waist region 36 and the back waistregion 38. For example, in the exemplary chassis 100 shown in FIG. 2, anelastic gathering member 159 may be attached at or adjacent to theproximal edge 157 of each of the leg cuffs 147 and extends into both thefront waist region 36 and the back waist region 38.

In various embodiments, each cuff elastic gathering member 159 may beenclosed inside a folded hem 170 for example. In various embodiments,the cuff elastic gathering members 159 may be sandwiched between twolayers forming the leg cuff 147, by two layers of the chassis 100, ormay be attached on a surface of the chassis 100 or the leg cuff 147 andremain exposed.

In one embodiment, when stretched, the cuff elastic gathering member 159disposed adjacent to each leg cuff's proximal edge 157 allows the legcuff proximal edge 157 to extend to the flat uncontracted length of thechassis 100, e.g., the length of the chassis 100, as shown in FIG. 1.When allowed to relax, the cuff elastic gathering member 159 contractsto pull the front waist region 36 and the back waist region 38 towardeach other and, thereby, bend the pant 20 into a “U” shape in which theinterior of the “U” shape may be formed by the portions of the pant 20that are intended to be placed toward the body of the wearer (i.e.,interior surface 102). Because each of the proximal edges 157 remainsfree between the longitudinally oriented leg cuff attachment zones, thecontractive force of the elastic gathering member 159 may lift theproximal edge 157 of the leg cuff 147 away from the interior surface 102of the chassis 100. This lifting of the proximal edges 157 when the pant20 is in the relaxed condition lifts the leg cuffs 147 into a positionto serve as side barriers to prevent, or at least inhibit, leakage ofbodily exudates.

In one embodiment, referring to FIGS. 2, one or more (specificallyincluding one, two, three, or four elastic strands per leg cuff 147)elastic strands 168 a and 168 b may be attached at or adjacent the sideedges 137 a and 137 b of the chassis 100 or the distal edge 139 of theleg cuff 147. When allowed to relax, the elastic strands 168 a and 168 bmay gather the side edges 137 a and 137 b of the chassis 100 and/ordistal edges 139 of the leg cuff 147 to form side barriers and functionas a second barrier to leakage of bodily exudates (e.g., urine and fecalwaste).

In various embodiments, the leg cuff 147 may be formed into a cuff flap631 and a side barrier 633. Particularly, a side barrier attachment zone630 may be oriented between the elastic gathering member 159 and elasticstrands 168. The placement of side barrier attachment zones 630 a and630 b relative to the longitudinal axis 42 may have a direct and coupledeffect on the depth of cuff flaps 631 a and 631 b and the size of theside barriers 633 a and 633 b. For example, as illustrated by FIG. 2,when the side barrier attachment zone 630 is moved laterally inward, thedepth of the cuff flaps 631 may decrease and the size of the sidebarrier 633 may increase. Conversely, when the side barrier attachmentzone 630 is moved laterally outward, the depth of the cuff flaps 631 mayincrease and the size of the side barriers 633 may decrease. The depthand/or size of the cuff flaps 631 and side barriers 633 may be adjustedfor various applications to provide enhanced functionality. In one suchembodiment, it has been found that reduced depth cuff flaps 631 andlarger side barriers 633 provide better application ease with regard toa pull-on pant-style application. This configuration may increase thesize of the leg opening enabling the wearer to step into the diaper 20more easily. In another embodiment, it has been found that increasingthe depth of the cuff flaps 631 and reducing the size of the sidebarriers 633 may provide improved leakage protection and increasedperception of capacity.

For embodiments wherein the leg cuffs 147 are formed by attachingadditional layers to the chassis 100 at or adjacent to each of therespective side edges 137 a and 137 b of the chassis 100, the one ormore elastic strands 168 a and 168 b may be oriented and attachedbetween the layers (e.g., layers forming the backsheet 83 and leg cuff147).

Waistband

In one embodiment, referring to FIGS. 3 and 8, the pant 20 formed fromthe absorbent article 10 may comprise an elasticized waistband 82.

In one embodiment, the elasticized waistband 82 may provide improved fitand containment and may be configured to elastically expand and contractlaterally to dynamically fit a wearer's waist. The elasticized waistband82 may extend longitudinally outwardly from the waist edge of the pant20 toward the waist edge of the absorbent core 200. In one embodiment,the pant 20 may have two elasticized waistbands 82, one positioned inthe back waist region 38 and one positioned in the front waist region36, although other pant embodiments may be constructed with a singleelasticized waistband 82. The elasticized waistband 82 may beconstructed in a number of different configurations including thosedescribed in U.S. Pat. Nos. 4,515,595 and 5,151,092.

In one embodiment, the elasticized waistbands 82 may comprise materialsthat have been “prestrained” or “mechanically prestrained” (i.e.,subjected to some degree of localized pattern mechanical stretching topermanently elongate the material). The materials may be prestrainedusing suitable deep embossing techniques. In other embodiments, thematerials may be prestrained by directing the material through anincremental mechanical stretching system as described in U.S. Pat. No.5,330,458. The materials may then be allowed to return to theirsubstantially untensioned condition, thus forming a zero strain stretchmaterial that is extensible, at least up to the point of initialstretching. Examples of zero strain materials are disclosed in U.S. Pat.Nos. 2,075,189, 3,025,199, 4,107,364, 4,209,563, 4,834,741, and5,151,092,

Side Panels

In one embodiment, referring to FIGS. 1 and 2, the absorbent article 10may comprise side panels 189 attached at or adjacent the side edges 137of the chassis 100 in one or both of the front waist region 36 and/orthe back waist region 38. In various embodiments, each side panel 189may either be a discrete separate element affixed to the chassis 100 ormay comprise a unitary piece of material that is neither divided nordiscontinuous with an element of the chassis 100, for example, abacksheet, a topsheet, or as leg cuff. In various embodiments, a pair oflaterally opposed side panels 189 may be attached adjacent the laterallyopposing side edges 137 a and 137 b of the chassis 100 in the frontwaist region 36 and a longitudinally opposing pair of side panels 189may be attached at or adjacent the laterally opposing side edges 137 aand 137 b of the chassis 100 in the back waist region 38. The sidepanels 189 in the front waist region 36 may have the same lateral extentfrom the side edge 137 of the chassis 100 to the distal edge (alsoindicated as 137 a and 137 b) of each side panel 189 as thelongitudinally opposed side panels 189 in the back waist region 38 or,alternatively, the side panels 189 disposed in the front waist region 36may have different lateral extents as measured from the side edges 137of the chassis 100 to the distal edge of the side panel 189 than theside panels 189 disposed in the back waist region 38. When side panels189 are present, the distal edges 137 of the side panels 189 form aportion of the side edge 137 or the absorbent article 10. In variousembodiments, the side panels 189 may comprise a first nonwoven materiallayer 191, an elastomeric film layer 193, and a second nonwoven materiallayer 195. The film layer 193 may be disposed intermediate, or at leastpartially intermediate, the first nonwoven material layer 191 and thesecond nonwoven material layer 195.

In one embodiment, the side panels 189 may be substantially rectangularin shape or may be shaped in such a way as to provide an integral tabfor ease of opening and refastening to create the secondary waistopening circumference 61. The side panels 189 may be extensible orelastically extensible in the lateral direction and/or the longitudinaldirection, for example. In various embodiments, the side panels 189 maycomprise an elastomeric film, such a nonwoven, or a combination of filmand nonwoven. In one embodiment, the side panels 189 may also comprise aplurality of strand-like filaments and a nonwoven material, for example.The strand-like filaments may be elastically extensible in at least thelateral direction, for example. Suitable elastomeric side panels andabsorbent articles comprising such side panels are disclosed in U.S.Pat. Nos. 5,669,897, 5,899,895, 4,940,464, 5,246,433, 5,545,158,5,591,155, 5,897,545.

Side Edge Seam

In one embodiment, referring to FIGS. 3 and 8, the front waist region 36and the back waist region 38 of the absorbent article 10 may be joinedtogether to form the pant 20 having an initial waist openingcircumference 160 and two leg opening circumferences 62. The joining ofthe front waist region 36 with the back waist region 38 may compriseside edge seams 51 a and 51 b. Such side edge seams 51 may be formedwhere the front and back waist regions 36 and 38 are joined such thatthe interior surface 102 of the front waist region 36 faces the exteriorsurface 104 of the back waist region 38 in a face-to-face relationship,e.g., in a so-called overlap seam attachment. Such side edge seams 51are shown in FIGS. 3 and 8, for example. A finger tab 72 extendingoutwardly from the side edge seam 51 or bond forming the side edge seam51 may be folded laterally inward towards either the front waist region36 and/or the back waist region 38. Both of the side edge seams 51 maybe pre-closed, meaning that the side edge seams 51 are closed prior toremoval of the pant 20 from its package and, therefore, prior to beingdonned on the wearer. The initial waist opening circumference 160 andthe leg opening circumferences 62 may be opened at predeterminedseparation zones 59, as described in further detail herein. In oneembodiment, once broken, the side edge seams 51 may not be able to bere-closed to form a secondary waist opening circumference and secondaryleg opening circumferences without the use of the first fasteningcomponents 53.

In one embodiment, the bonds of the side edge seams 51 may comprisepermanent suitable bonds that are appropriate for the specific materialsemployed in construction of the pant 20. Suitable bond types maycomprise discrete bonds, such as sonic sealed bonds, heat sealed bonds,high pressure bonds, radio frequency bonds, adhesive or cohesive bonds,sewed bonds, autogeneous bonds, and combinations thereof, for example.In various embodiments, the permanent side edge seams 51 may be joinedby a predetermined pattern of heat/pressure or ultrasonic welds that areable to withstand the forces and stresses exacted onto the side edgeseams 51 during application and wear of the pant 20. The permanent sideedge seams 51 may be formed as disclosed in U.S. Pat. Nos. 5,779,831,5,772,825, 5,607,537, 5,622,589, 5,662,638, 6,042,673, and 6,726,792,for example. The aforementioned patents also disclose various processingmethods to produce pants.

Refastenable Member

In one embodiment, referring to FIGS. 1-8, the pant 20 of the presentdisclosure may comprise the side edge seam 51 (e.g., permanent bonds)that may form the initial waist opening circumference 160, a firstfastening component 53 disposed at or adjacent to the side edge seam 51,a second fastening component 55 disposed in the area defined between thefirst fastening component 53 and the longitudinal axis 42. The first andsecond fastening components 53 and 55 may be disposed on the samesurface of the pant 20 (i.e., exterior surface 104 or interior surface102) and/or in the same waist region (i.e., front waist region 36 orback waist region 38) of the pant 20. In one embodiment, a separationzone 59 a may be disposed in the same waist region 36 as the firstfastening component 53 a and a separation zone 59 b may be disposed inthe same waist region 36 as the first fastening component 59 b. In oneembodiment, the second fastening component 55 may not be a specificdistinct element and may form a portion of one or both of the interioror exterior surface of the pant 20, e.g., a portion of the backsheet 83,such that the first fastening component 53 may be attached to theportion of the pant 20 formed by the second fastening component 55. Inone embodiment, the first and second fastening components 53 and 55 arenot in contact with each other when packaged (i.e., prior to use).

In one embodiment, the first and/or the second fastening components 53and 55, respectively, may each comprise at least one of a fasteningsurface and an attachment surface. The fastening surface may comprise afastener, a fastening device, and/or a fastening composition, forexample. The fastening surface may be used to attach the fasteningcomponent to a fastening surface of another fastening component or toanother portion of the absorbent article 10 or the pant 20. Theattachment surface may be used to attach the first and/or secondfastening components 53 and 55 to the chassis 100, a portion of thefront waist region 36, or another portion of the absorbent article 10,for example. In one embodiment, the second fastening component 55 maynot comprise an attachment surface as it may be integrally formed withor may be a portion of the front waist region 36. In such an embodiment,the second fastening component 55 may still comprise a fasteningsurface, such that it can be attached to the first fastening component53.

In one embodiment, the first and second fastening components 53 and 55may be disposed on the exterior surface 104 of the absorbent article 10in the front waist region 36. In an alternative embodiment where theabsorbent article 10 comprises side panels 189, the first and secondfastening components 53 and 55 may be disposed on the surface of theside panels 189 in the front waist region 36, for example.

In various embodiments, each of the fastening components 53 and 55 maybe permanently bonded, formed with, or adhered or otherwise joineddirectly or indirectly to the pant 20 at locations laterally inward fromthe side edges 137 a and 137 b, in the front waist region 36. One ormore of the fastening components 53 and 55 may be permanently bonded orjoined at a location at or proximate to the side edges 137 of the pant20 by any suitable methods, such as adhesive bonding, sonic bonding,pressure bonding, thermal bonding or combinations thereof, for example.

In one embodiment, the first fastening component 53 and/or the secondfastening component 55 may be made of a suitable releasably engageablefastener. For example, the first and second fastening components 53 and55 may comprise mechanical fasteners, e.g., hook and loop fasteners,hook and hook fasteners, mechanical fasteners, macrofasteners, buttons,snaps, tab and slot fasteners, tape fasteners, adhesive fasteners,cohesive fasteners, magnetic fasteners, hermaphrodidic fasteners, andother suitable fasteners. Some suitable examples of fastening systemsand/or the fastening components 53 and 55 are discussed in U.S. Pat.Nos. 3,848,594, 4,662,875, 4,846,815, 4,894,060, 4,946,527, 5,151,092,5,221,274, 6,251,097, 6,669,618, 6,432,098, 7,101,359, and 7,407,468.

Non-Engagement Zone

In one embodiment, referring to FIGS. 1 and 2, for example, theabsorbent article 10 may comprise one or more non-engagement zones 54disposed on or forming a portion of the same surface and in the samewaist region as the first fastening components 53. In variousembodiments, the non-engagement zones 54 may be intended to prevent, orat least inhibit, the first fastening components 53 from becomingengaged with other elements of the absorbent article 10 when packaged.In certain embodiments, the non-engagement zones 54 may be in surface tosurface contact with a fastening surface of the first fasteningcomponents 53 when the pant 20 is packaged.

In one embodiment, the non-engagement zone 54 may be disposed laterallyinward of the first fastening component 53 as shown in FIGS. 1 and 2.The non-engagement zone 54 may be disposed at or adjacent the permanentside edge seam 51. In various embodiments, the non-engagement zones 54may comprise a film, a sheet, a coating, or another material that doesnot attach to or engage with the first fastening components 53. Suitablenon-engagement zone materials may comprise films of polyethylene orpolypropylene, Teflon, latex, non-tack adhesives, selective adhesives,cohesives, and other materials that do not engage with the firstfastening component 53.

Separation Zone

In order to minimize the level of tensile force required to tear open orseparate the pant 20 at a predetermined location for removal from thewearer, a separation zone 59 may be provided at or proximate to the sideedge seams 51. The separation zone 59 may be located in the intact,initial waist opening circumference 160 of the pant 20 in the same waistregion as the first fastening component 53 and the second fasteningcomponent 55, as shown in FIGS. 1-3 and 5-8, for example. In anembodiment, a portion of the separation zone 59 may be disposedlaterally inward of the first fastening component 53. For embodimentscomprising the first and second fastening components 53 and 55, aportion of the separation zone 59 may be disposed between the first andsecond fastening components 53 and 55 and may be disposed in the samewaist region as the first and second fastening components 53 and 55.

In one embodiment, the separation zone 59 may be located on the pant 20in any manner that provides the desired functionality and ease ofapplication and refastening. For example, a separation zone 59 may belocated laterally inward of the side edges 137 of the absorbent article10 in one or both of the front waist region 36 and back waist region 38.In various embodiments, the separation zone 59 may be disposed adjacentto or be included in the area encompassed by the fastening components 53and 55, for example. In various embodiments, the separation zone 59 maybe disposed between the first fastening component 53 and the secondfastening component 55. In other embodiments, a portion of theseparation zone 59 may be disposed laterally inward of the first sideedge seam 51 and the first fastening component 53 may be disposedbetween the side edge seam 51 and the first longitudinally extendingside edge 137 a, for example. In one embodiment, a portion of theseparation zone 59 may be disposed laterally inward of the firstfastening component 53 or the first fastening component 53 may bedisposed laterally inward of the separation zone 59. In otherembodiments, the first fastening component 53 may be disposed laterallybetween the first longitudinally extending side edge 137 a and the firstside edge seam 51 a.

While the separation zone 59 is illustrated as a dotted line in certainembodiments for simplicity, it will be understood that the separationzone 59 may, in fact, be a “zone” having an area verses a line. Theseparation zone 59 may be any suitable size for a particular pant. Inone embodiment, a caregiver may have an option of separating theseparation zone 59 at more than one place within the separation zone 59,for example.

In one embodiment, the separation zone 59 may be formed in a layer or alaminate of layers by any methods that encourage preferentially fractureor separation when stress is applied thereto. The separation zone 59 mayalso be formed by a variety of methods and may comprise a variety ofpatterns. In one embodiment, the separation zone 59 may comprise apattern providing greater strength in the cross-machine or lateraldirection (CD) than the strength in the machine or longitudinaldirection (MD), for example. This configuration may help to maintain apant-like form during application and use, and yet provide the ease ofopening to enable removal of the pant 20 or enable application as atraditional tape-style diaper rather than a pant. In other embodiments,the separation zone 59 may not comprised a weakened area, but instead,the area of the pant 10 surrounding the separation zone 59 may comprisea strengthened area, for example in such an embodiment, the transitionbetween the strengthened area and the adjacent area may form an area ofstress concentration which can be utilized to help propagate theseparation of the separation zone 59.

In one embodiment, each of the laterally opposing separation zones 59may comprise laterally opposing separation zone edges that may be formedin one of the waist regions 36 and 38 laterally inward of the firstfastening components 53. En such an embodiment, the separation zoneedges may intersect with the front waist end edge 136 laterally inboardthe side edge 137 and may intersect the side edge 137 of the absorbentarticle 10 at the margin of each leg opening 62. In other embodiments,the separation zone edges may also be disposed in other locations on theabsorbent article 10. For example, if the separation zone edgescontinued generally linearly toward the lateral axis 44, continuousportions of the pant 20 may remain in place around the legs of thewearer. When the separation zone edges are shaped to intersect themargins of the respective leg opening 62 as described above, tearing orseparating the pant 20 at both of the laterally opposing separation zoneedges may release the pant 20 from the waist and both legs of thewearer. In one embodiment, the separation zone 59 may comprise a firstseparation zone edge extending from the waist opening of the absorbentarticle 10 to one of the leg openings of the absorbent article 10, and asecond separation zone edge extending from the waist opening of theabsorbent article 10 to the laterally opposing leg openings of theabsorbent article 10. In various embodiments, the first and secondseparation zone edges and may be linear, non-linear, parallel, ornon-parallel.

In one embodiment, the separation zone 59 may comprises a bond, such asa sonic sealed bond, a thermal sealed bond, a high pressure bond, aradio frequency bond, an adhesive bond, a cohesive bond, a sewed bond,an autogenous bond, and a combination thereof, for example. In suchembodiments, the bond area may form an area of increased strengthforming an area of stress concentration immediately adjacent. This areaof stress concentration may help enable separation of the separationzone. In an alternative embodiment, the bond can be separated (notillustrated) to create the separation zone.

In one embodiment, the initial waist opening circumference 160 isconfigured to be opened by separating a first portion of the separationzone 59 from a second portion of the separation zone 59. The separationof the first portion of the separation zone 59 from the second portionof the separation zone 59 may create linear or non-linear separationedges through, or at least partially through, the separation zone 59.

In certain embodiments, a separation zone locator or visual signalcomprising one or more structural, graphical or textural elements may beprovided so a caregiver can clearly distinguish the separation zone 59from the remainder of the pant 20. For example, a separation zonelocator may be printed at or adjacent to the separation zone 59. In suchan embodiment, the presence of the visible separation zone locator mayprove helpful to the caregiver in locating the separation zone 59 foruse in removal of the pant 20.

In one embodiment, referring to FIG. 8, a finger tab 72 may be disposedat or adjacent the side edge seam 51 allowing the caregiver to use thefinger tab 72 to release the first fastening component 53 from theexterior surface 104 of the pant 20 (in one embodiment, by breaking theclosure bond) and, subsequently, to break the separation zone 59. Thefinger tab 72 may be disposed adjacent the first fastening component 53and extend beyond the side edge 137 of the pant 20. In otherembodiments, the finger tab 72 may form a portion of the surface onwhich the first fastening component 53 is disposed.

Accordingly, the finger tab 72 may be partially aligned with theseparation zone 59 as shown in FIG. 8. It should be appreciated,however, that the tab 72 may alternatively be positioned and arranged inany alternative manner that facilitates intentional opening of theseparation zone 59. For instance, the tab 72 may extend substantiallyalong the entire length of the separation zone 59. The tab 72 may beconfigured to be grasped by a caregiver when applying an opening orreleasing force to the first fastening component 53 and the separationzone 59 in order to sever the initial waist opening circumference 160and leg opening circumferences 62 to remove the pant 20 from the wearer.The tab 72 may also provide a visual grasping point and greater leveragefor the caregiver to open the first fastening components 53 and severthe separation zone 59 and, in some embodiments, the closure bond.

In one embodiment, the tab 72 may comprise any suitable indicia that canbe printed on the exposed surface of the tab 72 (i.e., the surface thatis visible when the pant 20 is being worn). Alternatively, the indiciamay be disposed on an auxiliary layer that is affixed to the tab 72, forexample. Accordingly, the indicia may be visible to a caregiver whowishes to remove the pant 20 from the wearer.

In one embodiment, suitable indicia may comprise graphics, writings,(e.g., “pull here” or “open here” or other suitable language thatcommunicates the use of the tab 72), regions that are coloreddifferently than surrounding pant 20 components, such as the chassis100, and combinations thereof that increase the visibility and intuitiveuse of the tab 72. Furthermore, the finger tab 72, the first fasteningcomponent 53, the non-engagement zone 54, the second fastening component55, and the separation zone 59 may comprise distinctively differentcolors, patterns, characters, or carry other identifying indicia thatprovides contrast between the various components, thereby increasingtheir visibility and communicating their intuitive use to the caregiver.In various embodiments, the indicia may comprise pictorial symbols,photographs, drawings, cartoons, and logos, for example. The indicia 76may also comprise a single icon or a series of the same or differenticons. Graphics other than the images described above may be used toattract a caregiver's attention and indicate a gripping location, asdescribed in U.S. Pat. Publ. Nos. 2006/0212010 and 2006/0212018, forexample.

As described above, the separation zone 59 may be configured to bebroken, separated, or severed, such that the caregiver may easilyseparate a portion of the front waist region 36 from itself or mayseparate a portion of the back waist region 38 from itself to inspectthe pant 20 for soiling or to initially apply the pant 20 in atraditional tape-style diaper fashion, if desired, and also to removethe pant 20 from the wearer after it has been soiled. In one embodiment,the separation zone 59 may have an opening force of less than about 5000grams, less than about 4000 grams, or less than about 3000 grams suchthat the caregiver can choose to break the separation zone 59 and removethe pant 20. Alternatively, the separation zone 59 may be left intactallowing a caregiver or a wearer to slide down the pant 20 from thewaist and legs similar to conventional underwear, for example.

In one embodiment, the separation zone 59 may comprise a notch or anotched portion (not illustrated). In one embodiment, the notch may helpget the separation or tearing of the two separation zone edges in anarea of the separation zone 59, for example. In various embodiments,indicia or graphics may be oriented on a portion of the separation zone59 (e.g., in the middle of the separation zone) such that the caregivertears or separates the separation zone in that desired location. In suchan embodiment, the separation may not be assisted by weakened areas,perforations, one material being positioned adjacent another material,etc. The resulting separation may be very rough, jagged, and/orunpredictable, for example.

EXAMPLE EMBODIMENTS

In one embodiment, referring to FIGS. 1-7, when the pant 20 is worn onthe lower torso of a wearer, the front waist end edge 136 and the backwaist end edge 138 of the chassis 100 may encircle a portion of thewaist of the wearer, while at the same time the side edges 137 a and 137b may encircle at least a portion of the legs of the wearer. At the sametime, the crotch region 37 may be generally positioned between the legsof the wearer and the absorbent core 200 may extend from the front waistregion 36 through the crotch region 37 to the back waist region 38.

Overlap Seam Progression Figures

In one embodiment, referring to FIGS. 9-13, 18, and 22, the absorbentarticle 10 may be folded about a lateral axis 44 to form a pant 20comprising overlap seams 58. The absorbent article 10 may comprise afront waist region 36 comprising a front waist end edge 136, a backwaist region 38 comprising a back waist end edge 138, one or more firstfastening components 53, one or more second fastening components 54, oneor more non-engagement zones 54, optionally, one or more closure bonds56, and a longitudinal axis 42. In one embodiment, the one or moreclosure bonds 56 may not be present until the absorbent article 10 isfolded about the lateral axis 44 and readied to be formed into the pant20. In various embodiments, the absorbent article 10 may comprise one ormore first fastening components 53 disposed in a first waist region andmay optionally comprise one or more second fastening components 55disposed in the same waist region as the first fastening components 53.The one or more second fastening components 55 may be formed as aportion of the first waist region, formed integral with a portion of thefirst waist region, or attached to or disposed on a portion of the firstwaist region. In one embodiment, more than two second fasteningcomponents 55 may be provided along an area of the first waist region,for example. In various embodiments, the first fastening components 53and the second fastening components 55 may be disposed in the same waistregion (e.g., the first waist region 36) and on the same surface of thesame waist region 36 (e.g., the exterior surface 104).

Now described is the progression of how the absorbent article 10 may beformed into the pant 20 (i.e., steps taken by the manufacturer). In oneembodiment, referring to FIG. 9, a simplified version of the absorbentarticle 10 is illustrated. While the absorbent article 10 is illustratedas being comprised of a single panel, those of will in the art willrecognize that the absorbent article 10 may be comprised of multiplepanels or components, such as topsheets, backsheets, containmentregions, absorbent cores, leg cuffs, waistbands, elastics, and/or sidepanels, for example. The simplified version is illustrated merely forsimplicity in the explanation of the progression of formation. To formthe pant 20, first, the absorbent article 10 is folded about the lateralaxis 44 such that the interior surface 102 of the front waist region 36is brought into a surface-to-surface facing position with the interiorsurface 102 of the back waist region 38. In one embodiment, thisconfiguration is illustrated in FIG. 10. As can be seen, a permanentside seam 51 may be formed to create an overlap seam. The overlappermanent side edge seam 51 may be created by bringing a portion of theinterior surface 102 of the front waist region 36 into asurface-to-surface orientation with a portion of the exterior surface104 of the back waist region 38 as shown in FIG. 10. Alternatively, theoverlap permanent side edge seam 51 may be created by bringing a portionof the exterior surface 104 of the front waist region 36 into asurface-to-surface orientation with a portion of the interior surface102 of the back waist region 38 as shown in FIG. 18 (see also FIGS. 1and 2). In other embodiments, the overlap permanent side edge seam 51may be created by bringing a portion of the interior surface 102 of thefront waist region 36 into a surface-to-surface orientation with aportion of the interior surface 102 of the back waist region 38 as shownin FIG. 22. In one embodiment, the bond used to form the permanent sideseam 51 may be formed by various methods, such as adhesive bonding,permanent cohesive bonding, thermal bonding, ultrasonic bonding orpressure bonding, for example. While in the configuration of FIG. 10,the front waist region 36 is joined to the back waist region 38 via theoverlap seams 58. A separation zone 59 may be formed between each firstfastening component 53 and each permanent side edge seam 51 in the frontwaist region 36. Optionally, in the step illustrated in FIG. 10, one ormore closure bonds 56 may be formed by various methods, such as adhesivebonding, cohesive bonding, thermal bonding, ultrasonic bonding orpressure bonding, for example. The closure bond 56 may be disposed onthe exterior surface 104 of the front waist region 36 at or adjacenteach side edge 137 and/or each first fastening component 53. Next, stillreferring to FIG. 10, the portions of the absorbent article 10comprising the overlap seams 58 and/or the first fastening components 53can be folded laterally inward, in a direction toward the longitudinalaxis 42. In one embodiment, the closure bonds 56 may hold the foldedover portion against the exterior surface 104 of the front waist region36 of the pant 20. In one embodiment, the fully formed pant 20 isillustrated in FIG. 10. As can be seen in FIG. 10, the fully formed pant20 comprises an initial waist opening circumference 160. In such anembodiment, the first fastening components 53 are not used to maintainor form the initial waist opening circumference 160 and, in fact, arenot fastenably engaged with the second fastening components 55 or otherportions of the pant 20 although they may be in surface-to-surfacecontact with the non-engagement zones 54. As discussed herein, thenon-engagement zones 54 prevent, or at least inhibit, the firstfastening components 53 from fastening with a portion of the pant 20when packaged in certain instances, the consumer (e.g., caregiver) wouldreceive the pant 20 in the configuration illustrated in FIG. 10.

In one embodiment, the caregiver, upon receipt of the pant 20 or removalof the pant 20 from a package (the pant 20, in one embodiment, being inthe configuration illustrated in FIG. 10), may decide to apply the pant20 as a pull-on training pant or as a type-style diaper. To apply thepant 20 as a pull-on training pant, the caregiver may use the pant 20like underwear and have the wearer place one foot in each leg openingsand pull the pant 20 up to an area about the wearer's waist. In thisconfiguration, the first fastening components 53 would not be fastenablyengaged with a portion of the pant 20 or with the second fasteningcomponents 55. Instead, the overlap seam 58 would maintain the initialwaist opening circumference 160 around the wearer's waist. If thecaregiver needs to check the pant 20 at any time during use by thewearer, the caregiver can pull on a portion of the pant adjacent theside edge 137 to separate or break the closure bond 56 and then rotatethe folded over portion away from the longitudinal axis 42 therebyseparating or tearing the separation zone 59. In one embodiment, theseparated or torn separation zones 59 are illustrated in FIG. 11. Invarious embodiments, one or more portions of the front waist region 36that have been separated from the remainder, central portion, of thefront waist region 36 may then be reattached to the front waist region36, similar to the example configuration illustrated in FIGS. 12 and 13.When the pant 20 is in the configurations of FIGS. 11 and 12, thecaregiver can check the pant 20 to determine if a pant change needs tobe made. If a pant change does not need to be made, the caregiver canrefasten the pant 20 by engaging the first fastening components 53 andthe second fastening components 55 with each other to create a secondwaist opening circumference 61. One embodiment of such engagement isillustrated in FIG. 13. In embodiments, where the separate secondfastening components 55 are not provided, the caregiver may engage thefirst fastening components 53 with another portion of the front waistregion 36 (e.g., the backsheet 83) forming the second fasteningcomponent 55.

In one embodiment, to apply the pant 20 as a type-style diaper, thecaregiver can pull on a portion of the pant adjacent the side edge 137to separate or break the closure bond 56 and rotate the folded overportion away from the longitudinal axis 42 thereby separating or tearingthe separation zone 59. In one embodiment, this configuration isillustrated in FIG. 11. Referring to FIG. 12, the pant 20 may then beunfolded about the lateral axis 44. When the pant 20 is unfolded, in oneembodiment, referring to FIG. 12, one or more portions of the frontwaist region 36 may remain attached to the back waist region 38. In thisconfiguration the pant 20 can be applied to the wearer like a tape-stylediaper. In one embodiment, the applied configuration is illustrated inFIG. 13. In FIG. 13, the first fastening components 53 are engaged withthe second fastening components 55 or other portions of the front waistregion 36 to create a second waist opening circumference 61.

EXAMPLE EMBODIMENTS

In one embodiment, referring to FIGS. 14-17, the laterally opposingpermanent side seams 51 may be disposed at or adjacent the side edges137 in one or both waist regions 36 and/or 38. In embodiments whereinthe lateral extent of the front waist region 36 is substantially equalto the lateral extent of the back waist region 38 during bonding of thepermanent side edge seams 51, the permanent side edge seams 51 may bedisposed at or adjacent the side edges 137 of the absorbent article 10in both the front and back waist regions 36 and 38. In one embodiment,the absorbent article 10 is folded at a laterally extending fold linedisposed in the crotch region 37 to bring the front waist region 36 andthe back waist region 38 into an interior surface to interior surface,face to face orientation. The permanent side edge seams 51 may be formedby placing the interior surface 102 of one of the waist regions 36 or 38in an overlapping relationship with the exterior surface 104 of theopposing waist region 36 or 38 adjacent the side edges 137 andsubsequently bonding the waist regions 36 and 38 together. The firstfastening component 53 may be applied to the absorbent article 10 priorto forming the permanent side edge seam 51. The second fasteningcomponent 55 may also be applied prior to forming the permanent sideedge seam 51 or after forming the permanent side edge seam 51. In thisembodiment, the first fastening component 53 and/or the non-engagementzone 54 may be disposed at least partially within the permanent sideedge seam 51 with the fastening surface of the first fastening component53 in a face to face surface to surface orientation with thenon-engagement zone 54. When removed from the package, the absorbentarticle 10 is in the form of the pant 20. The caregiver may apply theabsorbent article 10 to the wearer as a pant or as a tape-style diaperby first releasing the first fastening component 53 by separating thefront waist region 36 from the back waist region 38 by breaking thepermanent side edge seam 51 thereby opening the initial waist openingcircumference 160 (the closure bond 56 if present may also be broken,for example), then placing the back waist region 38 of the absorbentarticle 10 under the wearer and fastening the first fastening component53 to the second fastening component 55, another portion of the frontwaist region 36, or another portion of the absorbent article 10 tore-close the pant 20 on the wearer. In one embodiment, FIG. 15A is across-sectional view of the absorbent article 10 of FIG. 14, taken alongline A-A. In one embodiment, FIG. 15B is a cross-sectional view of theabsorbent article 10 of FIG. 14, taken along line B-B. In oneembodiment, FIG. 16 is a perspective view of the pant 20 formed with anoverlap seam. In various embodiments, FIG. 16 may comprise variousindicia or graphics 76 to indicate to a caregiver where to land orfasten the first fastening component 53 to create the second waistopening circumference. In one embodiment, the indicia or graphics 76 maybe shaped to illustrate various waist circumferences, for example. Inone embodiment, FIG. 17 is a cross-sectional view of the pant 20 of FIG.16, taken along line D-D.

In one embodiment, referring to FIGS. 18 and 19, the laterally opposingpermanent side seams 51 may be disposed at or adjacent the side edges137 in one or both waist regions 36 and/or 38. In embodiments where thelateral extent of one of the front or back waist regions 36 or 38 isgreater than the lateral extent of the opposing waist region 36 or 38 atthe point of bonding the permanent side edge seams 51, the permanentside edge seams 51 may be disposed at or adjacent the side edge 137 ofthe absorbent article 10 in one waist region 36 or 38 and disposedlaterally inward of the side edge 137 in the opposing waist region 36 or38. In one embodiment, the absorbent article 10 is folded at a laterallyextending fold line disposed in the crotch region 37 to bring the frontwaist region 36 and the back waist region 38 into an interior surface tointerior surface, face to face orientation. The permanent side edgeseams 51 may be formed by placing the interior surface 102 of one waistregions 36 or 38 in an overlapping relationship with the exteriorsurface 104 of the opposing waist region 36 or 38 adjacent the sideedges 137 and subsequently bonding the waist regions 36 and 38 together.The first fastening component 53 may be applied to the absorbent article10 prior to forming the permanent side edge seam 51. The secondfastening component 55 may also be applied prior to forming thepermanent side edge seam 51 or after forming the permanent side edgeseam 51. In this embodiment, the first fastening component 53 and thenon-engagement zone 54 may be disposed adjacent the permanent side edgeseam 51 with the fastening surface of the first fastening component 53in a face to face, surface to surface orientation with thenon-engagement zone 54. When removed from the package, the absorbentarticle 10 is in the form of the pant 20. The caregiver may apply thepant 20 to the wearer as a pant or as a tape-style diaper by firstbreaking the initial waist opening circumference 160, releasing thefirst fastening component (by breaking the closure bond 56 if present,for example), placing the back waist region 38 of the absorbent article10 under the wearer and fastening the first fastening component 53 tothe second fastening component 53, to a portion of the front waistregion 36, or to another portion of the absorbent article 10 to re-closethe pant 10 about the waist of the wearer to form a second waist openingcircumference. In one embodiment, FIG. 19 is illustrated with bothseparation zones 59 separated and a first side in the unattachedconfiguration and a second side in the reattached configuration.

In one embodiment, referring to FIGS. 20 and 21, the lateral extent ofthe absorbent article 10 in one of the waist regions 36 or 38 is greaterthan the lateral extent of the absorbent article 10 in the opposingwaist region 36 or 38 prior to bonding of the permanent side edge seams51, the permanent side edge seam 137 may be disposed at or adjacent theside edge 137 of the one of the waist regions 36 or 38 and be disposedlaterally outward from the side edge 137 of the opposing waist region 36or 38. In one embodiment, the absorbent article 10 may be folded at alaterally extending fold line disposed in the crotch region 37 to bringthe from waist region 36 and the back waist region 38 into an interiorsurface to interior surface, face to face orientation. In certainembodiments, a portion of the chassis 100 comprising the first fasteningcomponent 53 may be folded laterally inward thereby positioning thefastening surface of the first fastening component 53 in a face to face,surface to surface orientation with a non-engagement zone 54. Thelaterally inward folded portion of the chassis 100 comprising the firstfastening component 53 and/or the permanent side edge seam 51 isreleasably attached to the exterior surface 104 of the absorbent article10 to maintain the position of the first fastening component 53 until itis released by the caregiver (by breaking the closure bond 56, forexample). Subsequently, the permanent side edge seams 51 may be formedby bonding the interior surface 102 of one waist regions 36 or 38 to theexterior surface 104 of the opposing waist region 36 or 38. The firstfastening component 53 may be applied to the absorbent article 10 priorto forming the permanent side edge seam 51. The second fasteningcomponent 55 may also be applied prior to forming the permanent sideedge seam 51 or after forming the permanent side edge seam 51. Whenremoved from the package, the absorbent article 10 is in the form of thepant 20. The caregiver may apply the pant 20 to the wearer as a pant oralternatively the caregiver may apply the absorbent article 10 as atape-style diaper by first unfolding the laterally inwardly foldedportion of the chassis 100 (breaking the closure bond 56, for example),breaking the initial waist opening circumference 160, placing the backwaist region 38 of the absorbent article 10 under the wearer andfastening the first fastening component 53 to the optional secondfastening component 55, to a portion of the front waist region 36, or toanother portion of the absorbent article 10, thereby re-closing the pant20 about the waist of the wearer to form a second waist openingcircumference. In one embodiment, FIG. 21 is illustrated with bothseparation zones 59 separated and a first side in the unattachedconfiguration and a second side in the reattached configuration.

In one embodiment, referring to FIGS. 22 and 23, the lateral extent ofthe absorbent article 10 in one of the waist regions 36 or 38 is greaterthan the lateral extent of the absorbent article 10 in the opposingwaist region 36 or 38 prior to bonding of the permanent side edge seams51, the permanent side edge seams 51 may be disposed at or adjacent theside edge 137 of the one of the waist regions 36 or 38 and be disposedlaterally outward from the side edge 137 of the opposing waist region 36or 38. In one embodiment, the absorbent article 10 may be folded at alaterally extending fold line disposed in the crotch region 37 to bringthe front waist region 36 and the back waist region 38 into an interiorsurface to interior surface, face to face orientation. In certainembodiments, the portion of the chassis 100 comprising the firstfastening component 53 may be folded laterally inward therebypositioning the fastening surface of the first fastening component 53 ina face to face, surface to surface orientation with a non-engagementzone 54. The laterally inward folded portion of the chassis 100comprising the first fastening component 53 is releasably attached tothe exterior surface 104 of the absorbent article 10 to maintain theposition of the first fastening component 53 until it is released by thecaregiver (by breaking the closure bond 56, for example). Subsequently,the permanent side edge seams 51 are formed by bonding the interiorsurface 102 of one waist regions 36 or 38 to the interior surface 102 ofthe opposing waist region 36 or 38. The first fastening component 53 maybe applied to the absorbent article 10 prior to forming the permanentside edge seam 51. The second fastening component 55 may also be appliedprior to forming the permanent side edge seam 51 or after forming thepermanent side edge seam 51. When removed from the package, theabsorbent article 10 is in the form of the pant 20. The caregiver mayapply the absorbent article 10 to the wearer as a pant or as atape-style diaper by unfolding the laterally inwardly folded portion ofthe chassis 100 (by breaking the closure bond 56, for example), breakingthe initial waist opening circumference 160, placing the back waistregion 38 of the absorbent article 10 under the wearer and fastening thefirst fastening component 53 to the second fastening component 55, aportion of the front waist region 36, or a portion of the absorbentarticle 10 thereby re-closing the pant 20 about the waist of the wearerto form a second waist opening circumference. In one embodiment, FIG. 23is illustrated with both separation zones 59 separated and a first sidein the unattached configuration and a second side in the reattachedconfiguration.

Attorney Docket No. 11577P, filed on Jan. 20, 2010, naming Gary DeanLaVon as an inventor, generally discloses various acceptable productfeatures that may be implemented in the embodiments described in thepresent application. Specifically, the above-described embodiments may,as appropriate, comprise a fastening system and side panels as describedin Attorney Docket No. 11577P.

Method of Making

The following method of making description refers generally to FIGS.24-28 c. Like element references from above will apply below even ifthey are not illustrated in FIGS. 24-28 c. Some numbering from above mayalso overlap with numbering from below.

In one embodiment, a method of forming an absorbent article 10 in theform of a prefastened pant incorporates the use of an apparatus thatreconfigures the absorbent article 10 from an open partially assembled,unfastened configuration to a pre-fastened configuration during themanufacturing thereof.

In one embodiment, the apparatus comprises a plurality of foldingdevices 230 disposed on a transport device which is configured in theform of a wheel or drum as shown in FIGS. 24 and 25. During themanufacture of prefastened pants 20, the folding device 230 receives adiscrete absorbent article 10 in a flat, open, unfastened,configuration. The discrete absorbent article 10 is held in place onfolding arms 60 and 63. The folding device 230 is adapted to fold thediscrete absorbent article 10 from its flat open configuration to abifold configuration, to form pant 20, wherein the absorbent article 10is folded about the lateral axis 44 disposed in the crotch region 37,folding a first waist region of the absorbent article 10 in a directiongenerally toward the opposing waist region as shown in FIG. 26. Inaddition to folding the absorbent article 10 about the lateral axis 44,the folding device 230 can also fold one or more portions of theabsorbent article 10, for example portions of the side panels 189,disposed adjacent the longitudinally extending side edges 137 laterallyinward such that a portion disposed in a first waist region is placed inan overlapping face-to-face orientation with a portion of the absorbentarticle 10 in the opposing waist region as shown in FIG. 27 to form anoverlapping permanent side edge seam 51. When refastenable fasteningelements are disposed at or adjacent the longitudinally extending sideedges 137 in one or both of the waist regions 36 and 38, the foldingdevice 230 may fold the portion of the absorbent article 10 comprising afirst fastening component 53 toward the opposing waist region placingthe portion of the absorbent article 10 comprising the first fasteningcomponent 53 in a face-to-face, surface-to-surface relationship with aportion of the chassis 100 in the opposing waist region. The foldingdevice 230 may encourage the portions of the first waist region and theportions of the second waist region into contact to form a permanentside edge seam 51, examples of such permanent side edge seams are shownin FIGS. 28 a-c. The permanent side edge seam 51 may comprise anadhesive bond, a cohesive bond, a thermal bond, ultrasonic bond, apressure bond or any suitable bonding methods or devices. The foldingdevice 230 and/or the transport device 210 may comprise a retentiondevice intended to maintain the position of the absorbent article 10 onthe transport device 210 until the absorbent article 10 is removed forfurther processing, U.S. Pat. Publ. No. 2008/0083489 and U.S. Pat. No.5,779,831 generally disclose various acceptable embodiments for carryingout the process as described above and as described in the presentapplication's FIGS. 24-28 c. More specifically, the transport device(processing wheel), folding device (processing station), side panelfolding and seaming devices (gripper and sealer) as disclosed in U.S.Pat. Publ. No. 2008/0083489 and U.S. Pat. No. 5,779,831 may be used inthe process of the present application.

In one embodiment of the method of making, a continuous web comprising aplurality of interconnected backsheets 83 is combined with a series oflaterally opposing pairs of discrete side panels 189. The side panels189 may comprise a material that is elastically extensible and mayadditionally comprise a refastenable fastening component disposed on asurface of the side panel 189. The continuous web of interconnectedbacksheets 83 is subsequently joined with a continuous web comprising aplurality of interconnected topsheets 81. Discrete absorbent cores 200are disposed between the continuous backsheet 83 web and the continuoustopsheet 81 web thereby forming a plurality of interconnected absorbentcontainment assemblies. The web is severed to form a plurality ofdiscrete absorbent articles 10. The discrete absorbent articles 10 aredisposed in an unfolded and unfastened state, i.e., the first fasteningcomponent 53 and second fastening component 55 are unfastened. Thediscrete absorbent article 10 is transported in a machine direction andfolded longitudinally about the lateral axis 44 disposed in the crotchregion 37 such that the front waist region 36 and the back waist region38 are disposed in an internal surface 102 to internal surface 102,face-to-face relationship. A portion of the absorbent article 10comprising a first fastening component 53 in a first waist region isfolded laterally inward toward the second waist region and a portion ofthe absorbent article 10 comprising a non-engagement zone 54 disposed inthe second waist region is folded laterally inward toward the firstwaist region. The laterally folded portions of the absorbent article 10comprising the first fastening component 53 is disposed in anoverlapping, face-to-face relationship with the portion of the absorbentarticle 10 comprising the non-engagement zone 54. In such an embodiment,the fastening surface of the first fastening component 53 is broughtinto surface-to-surface contact with the non-engagement surface of thenon-engagement zone 54. The overlapping region may be subsequentlybonded to form a permanent side edge seam 51. The side edge seam 51 maybe formed by a thermal bond, ultrasonic bond, a pressure bond or othersuitable bonding methods or devices. A portion of one or both of thefirst fastening component 53 and non-engagement zone 54 may be disposedwithin the permanent side edge seam 51.

In an alternative embodiment of the method of making, a continuous webcomprising a plurality of interconnected backsheets 83 is combined witha series of laterally opposing pairs of discrete side panels 189. Theside panels 189 may comprise a material that is elastically extensibleand may additionally comprise a refastenable fastening componentdisposed on a surface of a side panel 189. The side panel 189 maycomprise a non-engagement zone 54 disposed on or forming a portion ofthe surface of the side panel 189. A portion of the side panel 189comprising a first fastening component 53 may be folded laterally inwardto position the first fastening component 53 in a face-to-face,surface-to-surface orientation with the non-engagement zone 54. Theattachment of the first fastening component 53 to the side panel 189 aswell as the folding of the side panel 189 may take place either beforeor after attaching the side panel 189 to the continuous web ofinterconnected backsheets 83. The continuous web of interconnectedbacksheets 83 is subsequently joined with a continuous web comprising aplurality of interconnected topsheets 81. Discrete absorbent cores 200are disposed between the continuous backsheet 83 web and the continuoustopsheet 81 web thereby forming a plurality of interconnected absorbentcontainment assemblies. The web is severed to form a plurality ofdiscrete absorbent articles 10. The discrete absorbent articles 10 aredisposed in an unfolded and unfastened state, i.e. the first fasteningcomponent 53 and second fastening component 55 are unfastened. Thediscrete absorbent article 10 is transported in a machine direction andfolded longitudinally about the lateral axis 44 disposed in the crotchregion 37 such that the first waist region and the second waist regionare disposed in an internal surface 102 to internal surface 102,face-to-face relationship. A portion of the absorbent article 10comprising a first fastening component 53 in a first waist region isfolded laterally inward toward the second waist region and a portion ofthe absorbent article 10 comprising a non-engagement zone 54 disposed inthe second waist region is folded laterally inward toward the firstwaist region. The laterally folded portions of the absorbent article 10in a first waist region comprising the first fastening component 53 isdisposed in an overlapping, face-to-face relationship with a portion ofthe absorbent article 10 disposed in the opposing waist region. Theoverlapping region may be subsequently bonded to form a permanent sideedge seam 51. The permanent side edge seam 51 may be formed by anadhesive bond, cohesive bond, thermal bond, ultrasonic bond, a pressurebond or other suitable bonding methods or devices. A portion of one orboth of the first fastening component 53 and non-engagement zone 54 maybe disposed within the permanent side edge seam 51.

In one embodiment of the method of making, a continuous web comprising aplurality of interconnected backsheets 83 is combined with a series oflaterally opposing pairs of discrete side panels 189. The side panels189 may comprise a material that is elastically extensible and mayadditionally comprise a refastenable fastening component disposed on asurface of the side panel 189. The side panel 189 may comprise anon-engagement zone 54 disposed on or forming a portion of the surfaceof the side panel 189. The attachment of the first fastening component53 and creation of the non-engagement zone 54 may take place eitherbefore or after attaching the side panel 189 to the continuous web ofinterconnected backsheets 83. The continuous web of interconnectedbacksheets 83 is subsequently joined with a continuous web comprising aplurality of interconnected topsheets 81. Discrete absorbent cores 200are disposed between the continuous backsheet 83 web and the continuoustopsheet 81 web thereby forming a plurality of interconnected absorbentcontainment assemblies. The web is severed to form a plurality ofdiscrete absorbent articles 10. The discrete absorbent articles 10 aredisposed in an unfolded and unfastened state, i.e. the first fasteningcomponent 53 and second fastening component 55 are unfastened. Thediscrete absorbent article 10 is transported in a machine direction andfolded longitudinally about the laterally extending axis 44 disposed inthe crotch region 37 such that the first waist region and the secondwaist region are disposed in an internal surface 102 to internal surface102, face-to-face relationship. A portion of the absorbent article 10comprising a first fastening component 53 in a first waist region isfolded laterally inward toward the second waist region and a portion ofthe absorbent article 10 comprising a non-engagement zone 54 disposed inthe second waist region is folded laterally inward toward the firstwaist region. The laterally folded portions of the absorbent article 10in a first waist region comprising the first fastening component 53 aredisposed in an overlapping face-to-face relationship with a portion ofthe absorbent article 10 disposed in the opposing waist region. Theoverlapping region may be subsequently bonded to form a permanent sideedge seam 51. The side edge seam 51 may be formed by an adhesive bond,cohesive bond, thermal bond, ultrasonic bond, a pressure bond or othersuitable bonding methods or devices. A portion of the side panel 189comprising the first fastening component 53 may be folded laterallyinward to position the first fastening component 53 in a face-to-face,surface-to-surface orientation with the non-engagement zone 54. Aportion of one or both of the first fastening component 53 andnon-engagement zone 54 may be disposed laterally inward of the permanentside edge seam 51.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

All documents cited in the Detailed Description are, in relevant part,incorporated herein by reference in their entirety. The citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present disclosure. To the extent that any meaningor definition of a term in the present disclosure conflicts with anymeaning or definition of the term in a document incorporated byreference, the meaning or definition assigned to the term in the presentdisclosure document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A method of making an absorbent article in the form of a refastenable pant comprising the steps of: attaching at least one first fastening component to a web comprising a plurality of interconnected side panels; attaching at least one second fastening component to a web comprising a plurality of interconnected backsheets; attaching a laterally opposing pair of elastomeric side panels to the web of interconnected backsheets at or adjacent the laterally opposing side edges of the backsheet; combining a backsheet, topsheet and absorbent core to form an absorbent containment assembly wherein the absorbent core is disposed between the backsheet and topsheet; severing the continuous web of interconnected absorbent articles thereby forming a plurality of discrete absorbent articles; folding the discrete absorbent articles about the lateral centerline bringing the interior surface of the front waist region into contact with the interior surface of the back waist region; folding one or more of the side panels laterally inward to bring the first fastening component into contact with a non-engagement zone; folding the laterally opposing pair of side panels in a first waist region toward the second waist region and folding the laterally opposing pair of side panels in the second waist region toward the first waist region forming an overlapped region between the first and second waist regions; and forming a permanent side edge seam bonding the first waist region to the second waist region in the overlapped region.
 2. A method of making an absorbent article in the form of a refastenable pant comprising the steps of: attaching at least one first fastening component to a web comprising a plurality of interconnected side panels; attaching at least one second fastening component to a web comprising a plurality of interconnected backsheets; forming a non-engagement zone on a surface of one or both of the side panels and backsheet; attaching a laterally opposing pair of elastomeric side panels to the web of interconnected backsheets at or adjacent the laterally opposing side edges of the backsheet; combining a backsheet, topsheet and absorbent core to form an absorbent containment assembly wherein the absorbent core is disposed between the backsheet and topsheet; severing the continuous web of interconnected absorbent articles thereby forming a plurality of discrete absorbent articles; introducing a plurality of discrete articles onto a transport device comprising a plurality of folding devices each discrete article having a front waist region with at least one first fastening component and at least one second fastening component, a back waist region and a crotch region disposed between the front waist region and back waist region; folding the discrete absorbent articles about the lateral centerline bringing the interior surface of the front waist region into contact with the interior surface of the back waist region forming a bi-folded absorbent article; folding the laterally spaced side panels disposed in a first waist region laterally inward toward a second waist region and folding the laterally spaced side panels disposed in a second waist region laterally inward toward a first waist region thereby forming an overlap region between the first waist region and the second waist region. forming a permanent side edge seam bonding the first waist region to the second waist region in the overlap region.
 3. The method of claim 2, wherein at least a portion of one or both of the first fastening component and non-engagement surface are disposed within the overlap region.
 4. The method of claim 2, wherein at least a portion of one or both of the first fastening component and non-engagement surface are disposed within the permanent side edge seam. 